Asphalt brick device and method of making same

ABSTRACT

The present invention provides an asphalt brick device and method of manufacture, the asphalt brick device used for repairing potholes and other roadway deformities, as provided in the present invention. An additional aspect of the present invention is to provide an asphalt brick device that is of predictable and readily-varied composition that reflects the characteristics of the targeted repair site, ambient conditions, logistical requirements such as delivery and sizing of the material, and operational requirements. Further, the asphalt brick device may be configured to be stackable to satisfy user-defined asphalt repair delivery and ordering requirements.

CROSS REFERENCE TO RELATED APPLICATIONS

This application cross-references U.S. patent application Ser. No.12/651,358 filed Dec. 31, 2009 entitled “Infrared Heating System andMethod for Heating Surfaces,” U.S. patent application Ser. No.13/167,888 filed Jun. 24, 2011 entitled “Asphalt Repair System andMethod,” U.S. patent application Ser. No. 13/742,928 filed Jan. 16, 2013entitled “System and Method for Sensing and Managing Pothole Locationand Pothole Characteristics,” and U.S. patent application Ser. No.13/777,633 filed Feb. 26, 2013 entitled “System and Method forControlling an Asphalt Repair Apparatus,” the disclosures of each areincorporated herein by reference in their entirety.

FIELD OF THE INVENTION

Embodiments of the present invention are generally related to roadwaymaintenance and repair, and, in particular, to an asphalt brick deviceand method of manufacture, the asphalt brick device used for repairingpotholes and other roadway deformities.

BACKGROUND OF THE INVENTION

Roadway repair and maintenance are a ubiquitous problem that imposefinancial obligations on roadway authorities and present annoyances, ifnot costly hazards, to motorists. Asphalt surfaces, such as roads,driveways and parking lots, may suffer damage through a combination ofinfiltrating and freezing water and the continuous impact from movingvehicles. For example, potholes are a recurring problem creatinginevitable damage to roadway surfaces from traffic, construction, andthe environment. The enormous number and variety of paved roads makes itdifficult for federal, state, and local municipalities to implementrepairs in a timely, cost effective and safe manner.

The repair of damaged asphalt roadways generally requires bulk asphalt.The bulk asphalt is conventionally made by mixing and heating anaggregate with a bituminous material. The aggregate may includematerials such as crushed stone, gravel, sand, silt and clay. Thebituminous material serves as a binding agent. The mixed aggregate andbituminous material is typically heated to a temperature in the range of250-325° F.

The use of bulk asphalt presents several challenges resulting ininefficiencies and varying effectiveness. For example, the bulk mixtureof asphalt is typically mixed and heated at some distance from theapplication site and transported by a dump truck. Because the asphalt isa loose mixture, the precise quantity of bulk asphalt required for aparticular surface repair or construction project can be difficult todetermine. Too little delivered bulk asphalt results in one or moreadditional dump truck trips with resulting idle repair crew time. Toomuch asphalt results in unnecessary transport costs. Furthermore, theloose mixture of heated bulk asphalt is generally difficult to store,handle and transport.

Bulk asphalt is conventionally manufactured in imprecise compositions ofaggregate and bituminous material or in compositions ill-suited for aparticular repair site or repair application. For example, bulk asphaltused in a parking lot preferably uses larger-sized (cheaper) aggregateversus a roadway, because a parking lot experiences less loading andwear than a roadway. Also, a repair site exposed to extreme temperaturecycles or ranges, such as a Texas highway, require more bindingbituminous material than a roadway site with more uniform temperatures,such as a highway within a mountainous tunnel in Utah. Currently, suchdissimilar repair sites are typically provided with similar bulk asphaltcompositions which is ineffective when applied over a broad range ofapplications. The economic efficiency, and the effectiveness, of asphaltrepairs could be increased if the bulk asphalt were provided inpredictable and readily-varied compositions that are fine-tuned andcustomized to specific repair site conditions and characteristics.

Some efforts have been made to improve the process of asphaltmaintenance and repair. For example, U.S. Pat. No. 5,827,008 to Smith etal. (“Smith”) discloses a pavement repair structure and method of repairfor forming a bond between vertical surfaces in asphalt pavement. Therepair structure comprises a flexible, internal layer that isimpregnated with an adhesive asphalt medium to define an elongatedstrip. An additive agent is incorporated in the asphalt medium to reducethe tackiness and lower the temperature sensitivity of the asphaltmedium. A cut in the asphalt pavement caused by either a saw or a jackhammer is sealed by using the repair structure to form a bond betweenthe vertical cut edge of the pavement and the patch of new asphalticconcrete mix. However, Smith fails to teach several novel features ofthe present invention, including an asphalt brick device that is ofpredictable and readily-varied composition that reflects thecharacteristics of the targeted repair site, ambient conditions,logistical requirements such as delivery and sizing of the material, andoperational requirements. Smith is incorporated herein by reference inits entirety.

U.S. Pat. No. 5,556,225 to Marino (“Marino”) discloses a method ofrepairing multiple backfilled utility cut trenches, potholes, and otherdiscontinuities in asphalt pavement in which the pavement discontinuityis bridged by layers of heated virgin bituminous concrete of differentgrades, each layer including aggregate stone mixed with a liquid asphaltbinder. Alternatively, substantially non-polymerized thermoplasticbituminous concretes of different grades may be used to form thebridging layers, each layer including aggregate stone mixed with aliquid asphalt binder and preferably also containing fractions ofn-pentane soluble asphalts and being repetitively softenable in responseto repetitive applications of infrared radiation. However, Marino failsto teach several novel features of the present invention, including anasphalt brick device that is of predictable and readily-variedcomposition that reflects the characteristics of the targeted repairsite, ambient conditions, logistical requirements such as delivery andsizing of the material, and operational requirements. Marino isincorporated herein by reference in its entirety.

European Pat. Appl. No. 2,213,799 to Mainenti (“Mainenti”) discloses ablock for repairing a road surface wherein the block includes at leastone portion of pre-compressed asphalt. A method for the production of ablock suitable for repairing an asphalt road surface comprises the stepsof prearranging a mold having a shape corresponding to the portion ofpre-compressed asphalt to be obtained; pouring into the mold a mass ofasphalt; subjecting the mass to compression, so as to obtain the portionof pre-compressed asphalt, and removing the portion from the mold.However, Mainenti fails to teach several novel features of the presentinvention, including an asphalt brick device that is of predictable andreadily-varied composition that reflects the characteristics of thetargeted repair site, ambient conditions, logistical requirements suchas delivery and sizing of the material, and operational requirements.Mainenti is incorporated herein by reference in its entirety.

U.S. Pat. No. 4,684,288 to Chapa (“Chapa”) discloses a pavement tilecomprising a section of reinforcing geotextile fabric coated on a topside with asphalt adhesive and a layer of asphalt aggregate mix or “hotmix” over the adhesive. The asphalt aggregate mix is compacted to adesired thickness and degree of compaction. Asphalt is applied over abottom side of the fabric, and a peelable backing applied over theasphalt. For repair of deteriorated pavement, the protective backing ispeeled off, and the pavement tile applied over the deteriorated spot ofwear course. New paved surface or large repairs can be made by simplyadjoining tiles. The tiles are preferably made in batches. A large sheetis spread with the layers of asphalt adhesive and asphalt aggregate mix,and compacted. The large sheet is cut into tiles, and the asphalt andbacking applied to individual tiles. However, Chapa fails to teachseveral novel features of the present invention, including an asphaltbrick device that is of predictable and readily-varied composition thatreflects the characteristics of the targeted repair site, ambientconditions, logistical requirements such as delivery and sizing of thematerial, and operational requirements. Chapa is incorporated herein byreference in its entirety.

Effective and efficient repair of asphalt roadway surfaces using bulkasphalt could be significantly enhanced if the bulk asphalt was providedin predictable and readily-varied compositions that reflect thecharacteristics of the targeted repair site, ambient conditions,logistical requirements such as delivery and sizing of the material, andoperational requirements. Thus, there is a long-felt need for an asphaltbrick device and method of manufacture, the asphalt brick device usedfor repairing potholes and other roadway deformities, as provided in thepresent invention. An additional aspect of the present invention is toprovide an asphalt brick device that is of predictable andreadily-varied composition that reflects the characteristics of thetargeted repair site, ambient conditions, logistical requirements suchas delivery and sizing of the material, and operational requirements.Further, the asphalt brick device may be configured to be stackable tosatisfy user-defined asphalt repair delivery and ordering requirements.The asphalt brick device and method of manufacture provides severalbenefits, to include providing a more effective and efficient repair ofasphalt roadways thereby yielding a more cost and time effectiveutilization of material, labor, and equipment. For example, the ease ofmeasuring the quantity of bulk asphalt required for a particular job andthe ease of handling the asphalt brick device reduces labor time onsite.

SUMMARY OF THE INVENTION

It is thus one aspect of the present invention to provide an asphaltbrick device and method of manufacture, the asphalt brick device usedfor repairing potholes and other roadway deformities, as provided in thepresent invention. An additional aspect of the present invention is toprovide an asphalt brick device that is of predictable andreadily-varied composition that reflects the characteristics of thetargeted repair site, ambient conditions, logistical requirements suchas delivery and sizing of the material, and operational requirements.Further, the asphalt brick device may be configured to be stackable tosatisfy user-defined asphalt repair delivery and ordering requirements.

In one aspect of the invention, an asphalt brick device having apredetermined shape is disclosed, the asphalt brick device having apredetermined shape comprising: a body having an upper surface, a lowersurface, a front surface and a rear surface to define a specific shape;wherein the body comprises an aggregate and a binding agent of auser-selected relative proportion by one of volume and of weight basedon pre-determined calculations; wherein the aggregate and binding agentare mixable when the body is in a first state; wherein when the asphaltbrick device is adapted to be transportable and stacked.

In another aspect of the invention, a method for manufacturing aportable asphalt brick device having a predetermined shape andconsistency is disclosed, the method comprising: receiving a quantity ofaggregate and a quantity of binding agent based on a pre-determinedlocation of ultimate use; heating the quantity of aggregate and thequantity of binding agent to a first temperature to form an asphalt mix;mixing the asphalt mix to obtain a substantially uniform composition;compressing the asphalt mix into a mold; forming at least one portableasphalt brick device in the mold; and cooling the at least one portableasphalt brick device below a second temperature.

In a further aspect of the invention, a method of using a preformedportable asphalt brick device to repair a road deformity is disclosed,the method comprising: determining the composition of the preformedportable asphalt brick device based on a geographic location of the roaddeformity; ordering the preformed portable asphalt brick device;manufacturing the asphalt brick device by mixing at least an aggregatematerial and a binding agent; forming a shape of the preformed portableasphalt brick device; transporting the preformed portable asphalt brickdevice to the repair site; heating the preformed portable asphalt brickdevice to form a paving repair substance; and repairing the repair siteusing the paving repair substance.

The term “asphalt”, “asphalt mix” and “asphalt cement” and variationsthereof, as used herein, refers to a composite material comprisingaggregate and a binder used in construction projects to include roadsurfaces, parking lots and airports.

The term “aggregate” and variations thereof, as used herein, refers tocoarse particulate material used in construction, to include crushedstone, gravel, sand, silt, slag, recycled concrete, geosyntheticaggregates and clay.

The term “binding agent” and variations thereof, as used herein, refersto any material or substance that holds or draws aggregate together toform a cohesive asphalt, to include bitumen and any “bituminousmaterial.”

The term “bulk asphalt” and variations thereof, as used herein, refersto asphalt provided in large quantities, typically by dump truck.

The term “automatic” and variations thereof, as used herein, refers toany process or operation done without material human input when theprocess or operation is performed. However, a process or operation canbe automatic, even though performance of the process or operation usesmaterial or immaterial human input, if the input is received beforeperformance of the process or operation. Human input is deemed to bematerial if such input influences how the process or operation will beperformed. Human input that consents to the performance of the processor operation is not deemed to be “material.”

The terms “determine”, “calculate” and “compute,” and variationsthereof, as used herein, are used interchangeably and include any typeof methodology, process, mathematical operation or technique.

The term “module” as used herein refers to any known or later developedhardware, software, firmware, artificial intelligence, fuzzy logic, orcombination of hardware and software that is capable of performing thefunctionality associated with that element.

The term “roadway” as used herein refers to roads of all capacity,whether private or public, of various pavement compositions to includeconcrete, asphalt, asphalt concrete, and reclaimed asphalt pavement.

The term “roadway anomaly” as used herein refers to any atypical ordegraded characteristic of a prototypical roadway, to include potholes,ruts, crowns, upheaval, raveling, shoving, stripping, grade depressions,and cracking of various types to include line cracking and alligatorcracking.

It shall be understood that the term “means” as used herein shall begiven its broadest possible interpretation in accordance with 35 U.S.C.,Section 112, Paragraph 6.

Accordingly, a claim incorporating the term “means” shall cover allstructures, materials, or acts set forth herein, and all of theequivalents thereof. Further, the structures, materials or acts and theequivalents thereof shall include all those described in the summary ofthe invention, brief description of the drawings, detailed description,abstract, and claims themselves.

This Summary of the Invention is neither intended nor should it beconstrued as being representative of the full extent and scope of thepresent disclosure. The present disclosure is set forth in variouslevels of detail in the Summary of the Invention as well as in theattached drawings and the Detailed Description of the Invention, and nolimitation as to the scope of the present disclosure is intended byeither the inclusion or non-inclusion of elements, components, etc. inthis Summary of the Invention. Additional aspects of the presentdisclosure will become more readily apparent from the DetailedDescription, particularly when taken together with the drawings.

The above-described benefits, embodiments, and/or characterizations arenot necessarily complete or exhaustive, and in particular, as to thepatentable subject matter disclosed herein. Other benefits, embodiments,and/or characterizations of the present disclosure are possibleutilizing, alone or in combination, as set forth above and/or describedin the accompanying figures and/or in the description herein below.However, the Detailed Description of the Invention, the drawing figures,and the exemplary claim set forth herein, taken in conjunction with thisSummary of the Invention, define the invention.

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying drawings, which are incorporated in and constitute apart of the specification, illustrate embodiments of the invention andtogether with the general description of the invention given above, andthe detailed description of the drawings given below, serve to explainthe principals of this invention.

FIG. 1A is a front perspective view of an asphalt brick device accordingto one embodiment of the invention;

FIG. 1B is a front elevation view of an asphalt brick device accordingto another embodiment of the invention;

FIG. 1C is a front elevation view of an asphalt brick device accordingto yet another embodiment of the invention;

FIG. 2 is a front perspective view of a mold system used to manufactureasphalt brick devices;

FIG. 3 is a flow diagram of an embodiment of a method for manufacturingasphalt brick devices; and

FIG. 4 is a flow diagram of an embodiment of a method for repairing anasphalt site using asphalt brick devices.

It should be understood that the drawings are not necessarily to scale.In certain instances, details that are not necessary for anunderstanding of the invention or that render other details difficult toperceive may have been omitted. It should be understood, of course, thatthe invention is not necessarily limited to the particular embodimentsillustrated herein.

DETAILED DESCRIPTION

FIGS. 1-4 show various aspects and embodiments of asphalt brick device 2of the present invention. Asphalt brick devices 2 may be used forrepairing an asphalt site such as a roadway. A user may manufactureasphalt brick devices according to site-specific repair requirements.

Referring to FIG. 1A, an asphalt brick device 2 is depicted comprisingupper surface 4, lower surface 6, left side 8, right side 10, front 12and rear 14. Asphalt brick device 2 comprises length L, height H andwidth W. Further, each of upper surface 4 and lower surface 6 comprise anon-uniform surface or textured surface, such as the waffle patterndepicted.

Referring to FIG. 1B, a front elevation view of an alternate embodimentof an asphalt brick device 2 is depicted. The asphalt brick device 2comprises upper surface 4, lower surface 6, left side 8, and right side10. Furthermore, the asphalt brick device comprises a stackable feature:a rectangular protrusion 16 on upper surface 4 and matching rectangularvoid 18 on lower surface 6. The rectangular void 18 is configured toengage the matching rectangular protrusion 16 of a second asphalt brickdevice 2 mounted on top of a first asphalt brick device 2. Statedanother way, the rectangular void 18 is a conforming void with respectto the rectangular protrusion 16.

Referring to FIG. 1C, a front elevation view of another alternateembodiment of an asphalt brick device 2 is depicted. The asphalt brickdevice 2 comprises upper surface 4, lower surface 6, left side 8, andright side 10. Furthermore, the asphalt brick device comprises astackable feature: a large rectangular void 18 with two adjacent smallrectangular protrusions 16 on upper surface 4 and matching largerectangular protrusion 16 and two adjacent small rectangular voids 18 onlower surface 6. The large rectangular void 18 is configured to engagethe matching large rectangular protrusion 16 of a second asphalt brickdevice 2 mounted on top of a first asphalt brick device 2.

The asphalt brick device 2 is of a precise quantity of material and isconfigured to be readily stackable and easily handled. The asphalt brickdevice 2 is of composition useful for the repair or reconstruction ofasphalt roadways, and is sized according to user requirements. Forexample, in one embodiment, the asphalt brick device 2 is sized toprovide one 5- or 10-pound unit of paving repair material, such as anasphalt mix. The asphalt brick device 2 is brick-shaped, as depicted inFIG. 1A, with length L of approximately 12 inches, width W ofapproximately 8 inches, and height H of approximately 4 inches.

In one embodiment, each side of the asphalt brick device 2 issubstantially smooth or uniform. In another embodiment, one or moresides of the asphalt brick device 2 are textured. The textured side(s)may be useful for locking asphalt brick devices 2 together when stacked,which, among other things, provides stability to the stack of asphaltbrick device 2 and helps to ensure safety of the stack. For example, thetextured side(s) may be advantageous when storing and/or transportingasphalt brick device 2 as it may prevent movement when asphalt brickdevice 2 are stacked on, for example, a pallet. In one embodiment, theupper surface 4 and lower surface 6 comprise any type of texture orthree-dimensional pattern suitable for providing a locking function whenstacked, as known to those skilled in the art.

In another embodiment, matching tongue and groove patterns may be usedon respective upper surface 4 and lower surface 6. For example, theupper surface 4 of asphalt brick device 2 comprises at least one tonguefeature while the lower surface 6 of asphalt brick device 2 has at leastone groove feature. When stacked, the tongue feature of one asphaltbrick device 2 is fitted into the groove feature of another asphaltbrick device 2.

In a further embodiment, the asphalt brick device 2 comprises a voidconfigured such that conventional tines of a forklift may fit or conformto the void. Stated another way, a conforming void may be formed on theasphalt brick device 2, for example, on the lower surface 6, to engageone or more tines of a forklift.

In one embodiment, the weight of the asphalt brick device 2 does notexceed regulatory standards for handling, such as those that may existby OSHA. In one embodiment, the weight of the asphalt brick device 2does not exceed 40 lbs.

In another embodiment, the asphalt brick device 2 is fitted with one ormore handles for ease of carrying by an individual or a machine such asa forklift. In another embodiment, a plurality of asphalt brick devices2 are assembled in a wrap, such as plastic wrap similar to that used,for example, when wrapping furniture for moving, so as to allow readytransport of the plurality of asphalt brick devices 2. In oneembodiment, a plurality of asphalt brick devices 2 are transportedtogether to form an integer or known quantity of bulk asphalt, e.g. a1/10 cubic yard of asphalt.

In another embodiment, the asphalt brick device 2 is scored on one ormore surfaces to enable a substantially controlled breaking of theasphalt brick device 2 into two or more pieces substantially along anaxis aligned with the scored portion. In this manner, a more accurateon-site means to measure and/or dispense a quantity of asphalt isprovided. In one embodiment, the scored portion is disposed on at leastone of the upper surface and the lower surface of the asphalt brickdevice 2, the scored portion enabling a substantially controlledbreaking of the body into two pieces substantially along an axis alignedwith the scored portion.

In one embodiment, the asphalt brick device 2 is marked by alphanumericfor identification of properties, such as weight, type, composition, anddate of manufacture. In one embodiment, the asphalt brick device 2 ismarked by shape and/or color to identify properties, such as weight,type, composition, and date of manufacture.

In another embodiment, the asphalt brick device 2 comprises one or moresensors that measure or monitor asphalt and/or roadway state. Forexample, a sensor may be a positional sensor that measures location inone or more dimensions, pressure in one or more axes, temperature,and/or stress/strain. The sensor may be active in that it transmits itsmeasurement, or passive in that only when pulsed or queried sensed datais provided. The sensor may be a fine particle, for example, ananoparticle. In such a manner, the asphalt brick device 2, once used aspart of an asphalt repair job, provides an embedded in-situ sensor atthe job site. After placement, the in-situ sensor may be calibrated withrespect to initial condition, to include, for example, position,orientation, temperature and pressure. A change in any of these initialcondition readings may be used to assess the roadway condition andidentify any new and/or returning roadway anomalies. For example, asensor which translates in a vertical direction beyond a selectablethreshold may indicate that a pothole has formed or has returned.Similarly, an increase in recorded pressure beyond a selectablethreshold may indicate adjacent roadway compression such as caused by anearby rut. Such a sensor-equipped asphalt brick device 2 may be used aspart of a broader system for sensing and managing pothole locations andpothole characteristics, as provided in U.S. patent application Ser. No.13/777,633.

Referring to FIG. 2, a front elevation view of a mold system 20 used tomanufacture a plurality of asphalt brick devices 2. Mold system 20comprises lid 24, base 30 and frames 22. Lid 24 comprises upper surface26 and lower surface 28. Base 30 comprises upper surface 32. Uppersurface 32 of base 30 may feature a textured surface, as depicted inFIG. 2.

The base 30 is configured to secure one or more frames 22, and isadaptable in that one or more frames 22 may be removed. FIG. 2 depictsan arrangement of eight (8) frames 22. Each frame 22 is configured tohold a user-selected quantity of unmixed aggregate and binding agent, ora user-selected quantity of mixed aggregate and binding agent. In oneembodiment, each frame 22 is configured to allow in-situ mixing ofunmixed aggregate and binding agent, and heating and/or cooling of mixedor unmixed aggregate and binding material.

The shape of each frame 22 is configured to form a particular shape ofasphalt brick device 2. For example, to form brick-shaped asphalt brickdevices 2, each frame 22 has a rectangular box shape, as depicted inFIG. 2. However, asphalt brick device 2 is not limited to brick-likeshapes. That is, asphalt brick device 2 can be any shape that allowsasphalt brick device 2 to be efficiently stacked and/or handled. Asphaltbrick device 2 may be, for example, brick-shaped, pie-shaped,disc-shaped, and those shapes as depicted in FIGS. 1B-C.

Lid 24 and/or base 30 may comprise textured surfaces so as to imparttexture to the asphalt brick device 2 contained within a particularframe 22. For example, base 30 may comprise a textured pattern, such asa waffle pattern as depicted in FIG. 2, on the upper surface 32, whichwould impart the waffle pattern to the lower surface 6 of a particularasphalt brick device 2. The weight of the material contained within agiven frame 22 would effect the pattern to the lower surface 6. Further,lid 24 may comprise textured surfaces so as to impart texture to theasphalt brick device 2 contained within a particular frame 22. That is,lid 24 may comprise a textured pattern on lower surface 28. When the lid24 is pressed against a particular frame substantially filled withmaterial such as aggregate and binding agent, the pressure, that is thecompression, between base 30 and lid 24 to the material contained withinthe frame 22 will effect the textured pattern to the upper surface 4 ofthe asphalt brick device 2.

The lid 24 and/or the base 30 may also comprise geometries so as to formnon-planar surfaces on, respectively, the upper surface 4 and the lowersurface 6 of an asphalt brick device 2 formed within a particular frame22. That is, to form, for example, the asphalt brick device 2 of FIG.1B, the lid 24 would comprise the rectangular protrusion 16 and the base30 would comprise the matching rectangular void 18.

In one embodiment, each of the lid 24 and the base 30 do not comprise auniform pattern or geometry on lower surface 28 and upper surface 32,respectively, such that different shapes and/or patterns may be formedon one or more of the asphalt brick devices 2 formed in a plurality offrames 22. Stated another way, a particular frame 22 may be fitted overan upper surface 32 of a portion of the base 30 with a textured pattern,while an adjacent frame 22 may be fitted over an upper surface 32 of anadjacent portion of the base 30 devoid of a textured pattern. Thus, oneasphalt brick device 2 would be formed with a textured bottom surface 6and another would be formed with a uniform or non-textured bottomsurface 6.

In another embodiment, one or more interior surfaces of one or moreframes 22 comprise a non-stick material such that a completed asphaltbrick device 2 may be more readily removed. Such a non-stick materialmay be any such material known to those skilled in the art that willurge a mixed aggregate and binding material composition from adhering toa mold.

In one embodiment, the mold 20 is manufactured of materials comprisingmetals, metal alloys and aluminum. In one embodiment, one or moreinterior surfaces of a frame 22 of the mold 20 comprise texture and/or apattern which may urge the removal of an asphalt brick device 2 from aframe 22.

Asphalt brick device 2 is comprised of aggregate and binding agent inselectable relative proportions by one of volume and of weight. Further,the aggregate may be of selectable screen size with a given tolerance ora combination of selectable screen sizes with a given tolerance.

In one embodiment, the asphalt brick device 2 is hot mix asphaltconcrete (HMA or HMAC) that is molded into the shape of a brick. HMA isa combination of different sized aggregates and asphalt cement, whichbinds the mixture together. HMA is generally composed of from about 93%to about 97% by weight of aggregate and from about 3% to about 7%asphalt cement. Table 1 provides examples of the composition of asphaltaccording to Asphalt Emulsion Handbook, Suit-Kote Corp, pg. 34. Forexample, asphalt brick device 2 may have a range of 4.5-7.8% bituminousmaterial with the remainder aggregate. Examples of aggregate include,but are not limited to, crushed stone, gravel, sand, silt, and clay.

In other embodiments, the asphalt brick device 2 is any asphalt concreteknown to those skilled in the art, to include HMA, warm mix asphaltconcrete (WMA), cold mix asphalt concrete, and mastic asphalt concreteor sheet asphalt. In some embodiments, the asphalt brick device 2comprises recycled rubber (e.g. styrene butadiene styrene), recycledtires, recycled asphalt (RAP), and alternative binders or polymers.

In one embodiment, the asphalt brick device 2 operates in a first stateand a second state, in which the first state is a moldable or mixablestate and the second state is a substantially solid state. The secondstate may be at a lower temperature than the first state. The secondstate may be adapted to be readily transportable and further, may beheated to form a paving repair substance.

TABLE 1 Example formulations of asphalt suitable for forming asphaltbrick device 2 Type 4 Type 5 Type 6 Mixture General limits Generallimits General limits requirements¹ percent passing percent passingpercent passing Screen sizes and tolerance¹ and tolerance¹ andtolerance¹ 50 mm (2″) 37.5 mm (1½″) 100 — 25 mm (1″) 95-100 — 100 — 12.5mm (½″) 70-90 ± 6 90-100 — 100 6.3 mm (¼″) 48-74 ± 7 20-70 ± 7  90-1003.2 mm (⅛″) 32-62 ± 7 15-70 ± 7 30-70 ± 7 0.85 mm (#20) 10-40 ± 7 10-40± 7 10-40 ± 7 0.425 mm (#40) 5-22 ± 7 5-22 ± 4 5-22 ± 4 0.180 mm (#80)1-7 ± 3 1-9 ± 4 1-11 ± 4 75 μm (#200) 0-3 ± 2 0-3 —  0-3 — Bituminous4.5-7.0 6.2-7.5 6.5-7.8 materials^(2,3) Typical uses Dense-gradedDense-graded Dense-graded Intermediate Truing & Fine top course levelingcourse Source: Adapted from Asphalt Emulsion Handbook, Suit-Kote Corp.,page 34 ¹Percentage based on total aggregate weight. ²Total emulsionpercentage based on total mix weight. Residue percentage is determinedby multiplying emulsion percentage by asphalt content percentage of theemulsion. ³When crushed air-cooled blast furnace slag is selected, theabove bituminous material content shall be increased approximately 25percent. Dense-graded mixes are best if mixed using high quality,fractured coarse and fine aggregate to ensure good stability of theproduced mix.

An embodiment of a method 40 for manufacturing asphalt brick devices 2is shown in FIG. 3. A general order for the steps of the method 40 isshown in FIG. 3. Generally, the method 40 starts with a start operation42 and ends with an end operation 52. The method 40 can include more orfewer steps or can be arranged in a different sequence than those shownin FIG. 3.

At a step 44, a quantity of aggregate and a quantity of binding agent(such as a bituminous material) are received and heated. The relativequantities of aggregate and binding agent, and the type(s) of aggregateand binding agent(s), are selectable. For example, the quantities and/orproportions may be selected from Table 1. The binding agent andaggregate are heated to a first temperature such that the binding agentand aggregate may be mixed to form a substantially uniform composition.In one example, the mixture includes about 5% bituminous material andabout 95% gravel by weight. The aggregate and bituminous materials areheated to a temperature of from about 250° F. to about 325° F. and mixedto create a substantially uniform asphalt mixture, i.e. an asphaltconcrete, which is moldable and with sufficient viscosity to be able tobe poured into a mold. In one embodiment, the first temperature is about250 degree F. The method then proceeds to step 46.

At a step 46, a selectable amount of the asphalt mixture produced instep 44 is poured into one or more mold frames 22 of a mold 20 andpacked as required. The selectable amount of asphalt material poured ordelivered into a given mold frame 22 may vary so as to ultimatelyprovide a selectable amount of finished asphalt brick device 2. In oneembodiment, the selectable amount of asphalt mixture provided to aplurality of mold frames 22 is not uniform between the mold frames 22.Stated another way, the amount of asphalt mixture is not the same amongall of the mold frames 22. In one embodiment, the selectable amount ofthe asphalt mixture provided to one or more mold frames 22 is suitablyprecise such that when packed or compressed there is substantially noexcess material. The method then proceeds to step 48.

At a step 48, the asphalt mix provided and/or packed into one or moremold frames 22 is allowed to cool from the first temperature of step 44to a second temperature so as to form one or more solid asphalt brickdevices 2. In one embodiment, the second temperature is roomtemperature. In one embodiment, the second temperature is anytemperature such that the asphalt brick devices 2 may be removed fromthe mold frames 22 without significant breakage and/or may be handledwithout risk of breakage.

At a step 50, the one or more asphalt brick devices 2 are removed fromthe one or more mold frames 22 of mold 20. In one embodiment, the lid 26of mold 20 is first removed, and the mold 20 is inverted such that theasphalt brick devices 2 fall out of the mold 20 by gravity. For example,lid 24 is removed and mold 20 is inverted so that the asphalt brickdevices 2 fall by gravity out of mold 200. In another embodiment, one ormore interior walls of the mold frames 22 vibrate to urge the separationof the asphalt brick devices 2 from the mold frames 22. In embodimentsof the asphalt brick devices 2 which are stackable, the asphalt brickdevices 2 may be stacked, for example, on pallets to be transported orstored. At the completion of step 50, the asphalt brick devices 2 areready for use. The method then proceeds to step 52 where the methodends.

In one preferred embodiment, the finished asphalt brick devices 2 are ofa relative proportion, by weight or by volume, of aggregate to bindingmaterial to within one (1) percentage point of specification. Forexample, if a user selected a finished asphalt brick device 2 of 95.5%aggregate and 4.5% binding material, the finished asphalt brick device 2will be between 94.5-96.5% and the binding material between 3.5-5.5%.This is an “aggregate/binder tolerance” of 1%. In a more preferredembodiment, the aggregate/binder tolerance is 0.5%. In a more preferredembodiment, the aggregate/binder tolerance is 0.1%.

In one preferred embodiment, the variability between finished asphaltbrick devices 2 with respect to relative proportion, by weight or byvolume, of aggregate to binding material is within one (1) percentagepoint. For example, for a particular batch of finished asphalt brickdevices 2, all will have between 95-96% aggregate and between 4-5%binding material. This is a “batch tolerance” of 1%. In a more preferredembodiment, the batch tolerance is 0.5%. In a more preferred embodiment,the batch tolerance is 0.1%.

In one embodiment, a controller controls one or more aspects of theheating, mixing, cooling, and removal of the asphalt brick devices 2while engaged in or with the mold 20. For example, a controller maycontrol the temperature profile for the heating, to include the rate oftemperature increase, the maximum temperature reached and length such atemperature is maintained, and the rate of decrease of the heating.Furthermore, the controller may control the mixing apparatus used to mixthe asphalt brick devices 2, to include, for example, the RPM of themixing and the duration of the mixing. A controller may also control thecooling parameters, such as duration and temperature of the cooling.Finally, the controller may control micro-vibration of one of moreinterior walls of the mold frames 22 so as to urge the separation of theasphalt brick devices 2 from the interior walls of the mold frames 22.In one embodiment, the controller utilizes control algorithms comprisingat least one of on/off control, proportional control, differentialcontrol, integral control, state estimation, adaptive control andstochastic signal processing.

The overall use of asphalt brick devices 2 to perform an asphalt repairmay be better understood in reference to the following illustrativeexample, which should not be construed as limiting the functional andoperational characteristics of asphalt brick devices 2.

An embodiment of a method 60 for repairing an asphalt site using asphaltbrick devices 2 is shown in FIG. 4. A general order for the steps of themethod 60 is shown in FIG. 4. Generally, the method 60 starts with astart operation 62 and ends with an end operation 78. The method 60 caninclude more or fewer steps or can be arranged in a different sequencethan those shown in FIG. 4. Some steps of the method 60 can be executedas a set of computer-executable instructions executed by a computersystem and encoded or stored on a computer readable medium.

In step 64, the repair site requirements are determined. The repair siterequirements are based on many parameters of the particularcharacteristics of the repair site, such as the humidity and temperatureof the site, the exposure of the site to weather extremes or gradients,the age and composition of the existing asphalt, the work crew involvedand repair capabilities available, cost, time, type of repair forexample a roadway or a parking lot, and volume/extent of repairs.Generally, the requirements for resurfacing a section of roadway on aninterstate highway subject to extreme temperature cycles would typicallyrequire an asphalt mix of relatively fine aggregate. In contrast, therequirements for patching several potholes in a city parking lot exposedto only moderate temperature cycles would typically require an asphaltmix of relatively larger, and less expensive, aggregate. As an example,in a scenario requiring the repair of seven moderately-sized potholes ina parking lot, it might be determined that 1 cubic yard of bulk asphaltmix is required of Type 4 mixture (per Table 1), with aggregate at 94%and binding material at 6%. This parking lot pothole scenario will becontinued through the description of the steps of method 60 forillustrative proposes.

In step 66, the requirements for one or more types of asphalt brickdevices 2 is determined. Here, the requirements for executing the repairare translated into a specific set of requirements for asphalt brickdevices 2. For example, continuing the above parking lot scenario, therequirement for 1 cubic yard of bulk asphalt mix of Type 4 mixture withaggregate at 94% and binding material at 6% is translated into an orderfor asphalt brick devices 2. Assuming asphalt brick devices 2 of the“brick” embodiment described above (of rectangular shape of dimension12×8×4 inch and thus of 0.22 ft³ volume), a total of 27 ft³/0.22ft³=121.5 brick-type asphalt brick devices 2 are required. In oneembodiment, such calculations may be implemented on a computer and/or beautomated.

In step 68, an order is placed for the one or more types of asphaltbrick devices 2. The order may be placed by any means of communication,to include by telephone, by cellular phone, text messaging, smart phonessuch as an iPhone and other forms of wireless communications. In theabove parking lot pothole example, an order for 122 brick-type asphaltbrick devices 2 of Type 4 mixture with aggregate at 94% and bindingmaterial at 6% would be placed. In one embodiment, such communicationsmay be implemented on a computer and/or be automated and may beintegrated with the calculations of step 66.

In step 70, the one or more types of asphalt brick devices 2 aremanufactured. The process for manufacturing may be the process of FIG.3. In the above parking lot pothole example, the 122 brick-type asphaltbrick devices 2 of Type 4 mixture with aggregate at 94% and bindingmaterial at 6% would be manufactured.

In step 72, the finished one or more types of asphalt brick devices 2are transported to the asphalt repair job site. Generally, a bulkquantity (by weight or by volume) of asphalt comprising multiple asphaltbrick devices 2 can be easily determined by counting the number ofunit-sized asphalt brick devices. Namely, in any surface repair orconstruction project, the number of unit-sized asphalt brick devices 2can be easily counted and therefore the precise quantity of asphalt usedin the project can be accounted for. Continuing the parking lot potholeexample, 122 brick-type asphalt brick devices 2 of Type 4 mixture withaggregate at 94% and binding material at 6% would be transported to theparking lot repair job site.

In step 74, the one or more types of asphalt brick devices 2 are heatedto the placing temperature (e.g., 250-325° F.) for use as a pavingrepair substance and positioned at the repair site. With respect to theparking lot pothole example, a subset of the 122 bricks are heatedappropriately to form a hot asphalt concrete repair substance andportioned near each of the seven potholes in need of repair.

In step 76, the one or more types of asphalt brick devices 2, as heatedand positioned at the repair site per step 74, are used to repair theasphalt roadway. With respect to the parking lot pothole example, asubset of the 122 bricks are used to repair the pothole. The method 60then ends at step 78.

In one embodiment, one or more additives are added to one or moreasphalt brick devices 2 on-site. Such additives may be specialized tothe on-site repair conditions or allow dynamic, on-site additionaltuning of the asphalt brick device 2 composition. For example, anadditional sealant may be added to one or more asphalt brick devices 2after heating and prior to use for road repair.

In one embodiment, the heating portion of step 74 is performed by aninfrared heater, such as that disclosed in U.S. patent application Ser.No. 12/651,358 and U.S. patent application Ser. No. 13/167,888. In oneembodiment, the heating portion of step 74 is performed by any meansknown to those skilled in the art, to include microwave heating andconductive heating and by energy sources known to those skilled in theart, to include propane.

Communications means and protocols may include any known to thoseskilled in the art, to include cellular telephony, internet and otherdata network means such as satellite communications and local areanetworks. As examples, the cellular telephony can comprise a GSM, CDMA,FDMA and/or analog cellular telephony transceiver capable of supportingvoice, multimedia and/or data transfers over a cellular network.Alternatively or in addition, other wireless communications means maycomprise a Wi-Fi, BLUETOOTH™, WiMax, infrared, or other wirelesscommunications link. Cellular telephony and the other wirelesscommunications can each be associated with a shared or a dedicatedantenna. Data input/output and associated ports may be included tosupport communications over wired networks or links, for example withother communication devices, server devices, and/or peripheral devices.Examples of input/output means include an Ethernet port, a UniversalSerial Bus (USB) port, Institute of Electrical and Electronics Engineers(IEEE) 1394, or other interface. Communications between variouscomponents can be carried by one or more buses.

Computer processing may include any known to those skilled in the art,to include desktop personal computers, laptops, mainframe computers,mobile devices and other computational devices.

What is claimed is:
 1. An asphalt brick device having a predeterminedshape, comprising: a body having an upper surface, a lower surface, afront surface and a rear surface to define a specific shape; wherein thebody comprises an aggregate and a binding agent of a user-selectedrelative proportion by one of volume and of weight based onpre-determined calculations; wherein the aggregate and binding agent aremixable when the body is in a first state; wherein when the asphaltbrick device is adapted to be transportable and stacked.
 2. The deviceof claim 1, wherein the body is configured to operate in a first stateand a second state, the first state a moldable state and the secondstate a solid state.
 3. The device of claim 2, wherein the first stateoperates above a first temperature and the second state operates below asecond temperature.
 4. The device of claim 3, wherein the firsttemperature is 250 degree F.
 5. The device of claim 1, wherein theaggregate is comprised of at least one of crushed stone, gravel, sand,silt and clay.
 6. The device of claim 1, wherein the binding agent iscomprised of a bituminous material.
 7. The device of claim 1, whereinthe binding agent is in the range of 4-8 percent by weight of the mixedaggregate and binding agent.
 8. The device of claim 1, wherein thespecific shape is of substantially rectangular shape.
 9. The device ofclaim 1, further comprising a textured surface on at least one of theupper surface and the lower surface.
 10. The device of claim 1, furthercomprising at least one protrusion on at least one of the upper surfaceand the lower surface and at least one conforming void on the oppositeof the at least one of the upper surface and the lower surface.
 11. Thedevice of claim 10, wherein the protrusion and conforming void enablestacking of the asphalt brick device upon another asphalt brick device.12. The device of claim 10, wherein the conforming void is on the lowersurface and is configured to engage tines of a forklift.
 13. The deviceof claim 1, further comprising a scored portion on at least one of theupper surface and the lower surface, the scored portion enabling asubstantially controlled breaking of the body into two piecessubstantially along an axis aligned with the scored portion.
 14. Thedevice of claim 1, wherein the asphalt brick device weighs no more than40 lbs.
 15. The device of claim 8, wherein the substantially rectangularshape is of approximate dimension 12 inches by 8 inches by 4 inches. 16.The device of claim 1, further comprising a nanoparticle sensor.
 17. Thedevice of claim 1, wherein the body is a plurality of bodies wrapped tofacilitate transport by a user.
 18. A method for manufacturing aportable asphalt brick device having a predetermined shape andconsistency, comprising: receiving a quantity of aggregate and aquantity of binding agent based on a pre-determined location of ultimateuse; heating the quantity of aggregate and the quantity of binding agentto a first temperature to form an asphalt mix; mixing the asphalt mix toobtain a substantially uniform composition; compressing the asphalt mixinto a mold; forming at least one portable asphalt brick device in themold; cooling the at least one portable asphalt brick device below asecond temperature.
 19. The method of claim 18, wherein the firsttemperature is 250 degree F.
 20. The method of claim 18, wherein themold is configured to form a plurality of the portable asphalt brickdevices comprising at least one protrusion on an upper surface and atleast one conforming void on a lower surface of each portable asphaltbrick device, the protrusion and conforming void enabling stacking ofthe asphalt brick device upon another asphalt brick device.
 21. Themethod of claim 20, wherein the mold is configured to form at least onescored portion on the upper surface of each asphalt brick device, thescored portion enabling a substantially controlled breaking of theasphalt brick device into at least two pieces substantially along anaxis aligned with the scored portion.
 22. The method of claim 18,wherein the at least one portable asphalt brick device comprise ananoparticle sensor.
 23. The method of claim 18, wherein the at leastone portable asphalt brick device is a plurality of portable asphaltbrick devices wrapped to facilitate transport by a user.
 24. A method ofusing a preformed portable asphalt brick device to repair a roaddeformity, comprising: determining the composition of the preformedportable asphalt brick device based on a geographic location of the roaddeformity; ordering the preformed portable asphalt brick device;manufacturing the asphalt brick device by mixing at least an aggregatematerial and a binding agent; forming a shape of the preformed portableasphalt brick device; transporting the preformed portable asphalt brickdevice to the repair site; heating the preformed portable asphalt brickdevice to form a paving repair substance; and repairing the repair siteusing the paving repair substance.
 25. The method of claim 24, whereinthe composition of the preformed portable asphalt brick device is basedat least upon the temperature and use properties of the geographiclocation of the road deformity.
 26. The method of claim 24, furthercomprising adding an additive to the paving repair substance.